Soap product and process of manufacture



Dec. 13, 1927.

D. R. LAMONT SOAP PRODUCT AND PROCESS OF MANUFACTURE Filed May 25, 1927 4 Shee-ts-Sheet l R O T N E V W BY {Z ATTORNEY Dec. 13, 1927.

D. R. LAMONT SOAP PRODUCT AND PROCESS OF MANUFACTURE 4 Shets-Sheet 2 Filed May 25, 1927 BY M AT'l ONEY Dec. 13, 1927. 1,652,900

p. R. LAMONT SOAP PRODUCT AND PROCESS OF MANUFACTURE Filed May 25, 1927 4 sheets-sheet s INVENTOR Dec. 13, 1927. 1,652,900

D. R. LAMONT SOAP PRODUCT AND PROCESS OF MANUFACTURE Filed May 25, 1927 4 Sheets-Sheet 4 NTOR ATTORNEY Patented Dec. 13, 1927. 1,652,900

UNITED STATES PATENT'OFFICE.

DALLAS R. LAMONT, F BROOKLYN, NEW YORK.

son rnonuc'r ANDPROGESS or MANUFACTURE.

Application'filed May 25, 1927. Serial No. 194,116.

The present invention relates to the prodish and often remains in a mass at the bot-. duction of a soap product in reasonably fine tom during the entire washing process. Un- 50 state of division, and it has to do particulardissolved soap frequently sticks to garments ly with a soap product of this class having being washed and appears -as a spot on the certain useful novel physical properties and laundered article. Also, in washing maZ- with a process of obtaining and controlling chines, a considerable amount of the soap these physical properties in the product. usually passes the washing machine undis- 55 The invention contemplates primarily a subsolved. The most quickly soluble and most stantially pure soap as ordinarily produced nearly completely soluble soap flakes are by the usual methodsof commercial manuthose which are the thinnest, and when the facture or such a soap with an appropriate flakes are thin enough to be soluble in hot amount of an alkaline material added, but water in a few seconds they are quite frail '00 which product, in its characteristic properand they break up during manufacture, ties such'as appearance, cleansing properties, shipment and use so that a considerable suds forming properties, and the like, is esamount of dust forms in the product. Soaps sentially a soap'as distinguished from soin finely divided condition, granulated called soap powders or washing powders soaps, shredded soaps, soap powders, and '65 which contain a predominating proportion the like, are usually dusty and cause of soda ash or similar ingred ent. The indiscomfort to the user. Such soaps tend vention'is, in a sense, related to the process to lump in water and remain partly un for the manufacture of a finely divided dry dissolved. Lumpy powders, flakes, etc., cansoap product as described in Patent 'No. not be poured or shaken out of the package 70 '1 .GJLSOG. assigned to the assignee of this with any degree of exactness as to amount. case. Tlie present invention is based on the ,They'frequently cake and agglomerate in thedscovery that a new product not heretofore carton and to be shaken out at all, require obtained in the art can be produced when the removal of a substantial piece of the carsoap of a certain character of composition ton. The product of the present invention 7 prepared in a certain way for treatment is is un form in particle size and is uickly used and when the several physical variables and completely soluble. it is freeowing of the process are at certain values, the limand does not lump or cake in the carton or its of which have now been reasonably well in water, and it is not dust-y. It possesses ascertained and are-set forth herein, and qualities which give it a usefulness not here- 80 that a product can be produced directly from tofore obtained in products of this class. A molten soap of the usual composition and description and defin tion of the product in heavy flowing but not particularly viscid terms of these qualities, in terms of the consistency ordinarily obtained in the manustructural and general physical properties facture of soap which is essentially different of the product which give it such qualities, as from products heretofore produced directly and a description and definition of the procfrom such molten soap. ess by which such product is obtained con- Soap "flakes, chips, and the like, are not stitute the subject matter of this applicaquickly and completely soluble in water of tion. temperature convenient for washing. When The drawings which constitute a part of the 118E131 p flakes m Poured mto Wilt? this application illustrate certain ofthe novel and surfed, Wen 111 q i warmfivater, physical properties of the product and show us may be seen for some tlme moving about n an apparatus i hi h th process f th the Water P y undissolved, and If not present invention can be successfully con stirred until completely dissolved some part ducted. In the said drawings, Figur 1 i "of the product collects iat the bottom of the a reproduction of a photomicrograph showing a group of typical particles taken from the regular commercial run of the preferred product of this invention; Figure 2 is a similar view showing the typical particle formation ordinarily obtained from the spray drying of the usual molten soap; Figure 3 is a similar view showing a typical transitional particle formation intermediate the formations shown in Figures 1 and 2; Figure at is a reproduction of a photomicrograph showing the hollow unitary particle structure; Figure 5 is an actual size photograph of a bulk of the referred product shown in Figure 1; and Figures 6 and 7 are views, somewhat diagrammatic, ot' the preferred form of apparatus in whch the process of the invention is conducted.

The process of the present invention in- 'volves a spray treatment and drying of an appropriate soap material under certain particular controlled process conditions. An apparatus in which the process may be conducted is shown in Figures 6 and 7. The apparatus consists basically of the principal drying or treating chamber 1. The molten soap is delivered into the tower 1 in the form of a spray by means of nozzles 2 located at appropriate intervals about the periphery of the upper end of the tower 1, as shown. The soap is delivered to the nozzles 2 through the soap line 3 which communicates with the soap mixing tanks or crutchers 4. The soap is withdrawn from the crutcher 4 by means of a suitable pump 5 and is forced through the heater 6 into line 3 and from thence to nozzles 2. The pump 5 maintains the'soap in line 3 and at the nozzles 2 at a pressure appropriate for properly spraying the soap, as it issues from the nozzles, into uniform and reasonably finely divided condition. The heater 6 is preferably provided with a thermostatic control device 7 which controls admission of heating steam to the heater and thus regulates the temperature of the soap discharged from the heater to a substantially constant proper value. The line 3 beyond the "heater 6 is steamjacketed, and the steam supplied to the line is regulatcdby an automatic pressure controlling device 8 which functions to maintain the steam at a pressure which is equivalent to the condensation pressure for steam at a temperature equal to that of the soap as it leaves the heater 6. With this arrangement the temperature of the soap leaving the heater remains the same until the soap is delivered into the tower 1 through the nozzles 2, and a uniform temperature of the soap at all of the nozzles 2 is assured.

The heated drying or treatin gas is sup-' plied to the tower 1 through uct 9 (best shown in Figure 7) which enters the top of the tower as shown. Inside of the tower under the discharge end of the duct 9 is tribute the incoming gas uniformly across the section of the tower and to restrict whirling and eddying of the 'gas as it enters the tower. The distributor 10 is positioned above-the soap nozzles 2 so that at the time the gas comes into contact with the soap particles issuing rom the nozzles it is distributed reasonab uniformly across the tower and is proceeding downwardly through the tower in an orderly manner of flow without substantial whirling or eddying. Thus, the particles of the sprayed.

liquid soap are carried downwardly in orderly positively controlled flow through the tower by the drying gas. The drying gas comes into contact with all of the sprayed particles of soap at substantially the same temperature, and all of the particles are positively propelled through the tower so that every particle is subjected to a similar treatment by the drying gas for a substantially similar length of time. As here shown, the heated treating gas supplied to the tower 1 through duct 9 consists of products of combustion from the oil burning furnace 11 diluted and reduced to the proper temperature by air admitted to the system through the damper controlled opening 18. Further dampers 19 and 20 are provided for facilitating operation and permitting ready rcgulation and control of air volumes and air temperatures. The entire contents of the tower are continuously discharged through the outlet opening 13 at the bottom of the tower and from thence are conveyed or elevated to any desired point in the plant by being caused to flow through the discharge duct 14. Duct 14; leads to the collector 15 here shpwn as a centrifugal or cyclone type of collector, which receives the mixed gas and dry product issuing from the tower 1 and delivers the dry product through discharge outlet 16 at the bottom of the collector and sends the spent gas to waste through the outlet 17 at the top of the collector. The finished prod uct discharged from the collector 15 may be conveyed as desired to storage bins, from whenceit may be withdrawn forpackaging and shipment.

An appropriate operating panel and instrument board is provided at the operating platform at the top of the tower as indicated at 21. This instrument board 21 is provided as shown with recording instruments to indicate and keep a record of the process conditions. The instruments marked T T and T record the gas temperatures in the system. These temperatures are taken at the places in the tower indicated by the dotted line connections with the instruments. T is the initial temperature of the treating gas as it enters the top of the tower and first contacts with the sprayed soap issuing from' the nozzles 2. T is an indication of the temperatures at one or more points .along-the'length of the tower, here shown as at, two points, one substantially at the bottom of the tower and the other at a little distance from the bottom. T is the tem- 5 perature of the gas and dry product entering the collector. The temperature of the soap as it is delivered to the nozzles 2 is indicated on the temperature recording instrument T,. This temperature T is taken before the soap enters the individual nozzle pipes 2, which pipes extend a distance of say four feet into the hot tower so that the soap in passing along to the nozzles receives a somewhat furtherpreheating than is indicated by the T reading. .The pressures on the soap in the line ahead of the nozzles is indicated on the pressure recording instrumlent P, and a control 22 is located on the instrument board for controlling the speed of the pump 5 to thus permit regulation of the pressure on the soap to exactly the proper value.

The particular object of the present proc- 058 is the production of a new type of soap product characterized by the novel and desirable physical properties above referred to. l have discovered that by using the usual high solid content soap of ordinary manufacture and by setting and controlling certain of the process variables within certain limits such properties are obtained and can be controlled or varied in a given kind of soap product by an appropriate control or variation of the process conditions. The particular process conditions, which I have discovered can be manipulated to produce the new kind of product referred to, are

principally the initial air temperature (T,) and the soap ten'iperature (T,). To best describe the effect. of these process conditions when controlled to certain values and to describe the correlation and cooperation of these conditions with each other and with certain other of the process variables, particularly the soap pressure (R), in producmg the new product of this invention it is :desirable to describe at this point the product in terms of those physical properties which give it its novel and useful qualities.

One characteristic property of the product is a generally globular or rounded particle shape. The particles of the present productare not ordinarily perfect geometric spheres. They are characteristically of near-spherical, ball-like, generally globular, potato shaped reasonably smooth, rounded conformation, substantially as illustrated in the Figures 1, 4 and 5 of the drawings, as distinguished particularly from, an irregular, sharp cornered, fragmentary, roughened, granular, shredded or extenuatedparticle formation. This typical generally globular formation is shown in Figure 1.

A property of importance, present in combgiation with the rounded particle form,

Cit

is the particle size. The individual rounded particles which make up the product are of size readily perceptible to the naked eye. Each particle stands out to the eye as an independent unit, and the product appears as an aggregation of these independently.

visible little balls of soap arranged in close- 1y packed relation but nevertheless with visible interstices between particles whichserve to emphasize the size, the rounded generally globular shape and the individual character of the component particles. This combination of rounded particle shape and relatively larger particle size gives to the product a characteristic appearance that at once sharply distinguishes it from a powder product, a pulverized product, or a shredded product, and definitely characterizes it as a new form of product essentially different from the usual soap products at present commercially available. This size property. particularly in combination with the generally globular particle shape, is of importance in giving the product its free-flowing,

non-cal ing and non-lumping, and dust-free qualities.

The actual size .of the particles may be controlled as desired within reasonable limits, and it may be desirable for certain reasons to control the particle size to different values for different grades of products in tended for different uses, both for utility and so that the purchasing public may come to associate a certain particle size with a prodnot of a certain class. In one type of preferred product which I have produced the average particle is about 0.75 mm. in diameter. ,A product composed of particles of this size definitely possesses the characteristic appearance and other properties above described which identify it as a new product different from the usual powder soaps, pul-' verized soaps, soap flakes, soap powders, and the like. A product having this particle size is shown in Figure 1, magnified, and in Figure 5 as seen by the eye. Vith an average particle size of about Q,75 mm., and with the uniformity of particle size obtainable by the present process, the bulk of the product will pass through a 20 mesh sieve in which the openings are 1 mm. square while the bulk of the product is retained on a 40 mesh sieve in which the openings are 0.5 mm. square. I

. have produced from soap of the same composition as that used in producing the product 0.75 mm. average particle diameter, a prodnot in which the average particle was approximately 1.5 mm. in diameter. With this particle size the bulk of the product passes a 10 mesh sieve, wherein the openings are 2 mm.

square, but is retained on a 20 mesh-sieve. It is-also possible by the present process to produce a product having a smaller particle size. A reasonable minimum particle size which gives a fine grained product yet a lie product which unquestionably retains the least as great as the minimum value just given, products with still smaller particle sizes can be produced. WVith the present characteristic smooth rounded particle structure, even when the particle size is quite small, the product appears different from the average powder product-particularly in its smoothness and uniformity of texture, its free-flowing characteristics, its freedom from dust and its freedom from any tendency to mass or pack in the carton. The balllike particle structure is evident to the eye to a certain extent even with quite small particles. A product having an average particle size of about 0.2 mm., which is well below the minimum preferred particle size, appears at a little distance as a practically smooth, fairly fine-grained powder product, but upon nearer observation can, with the naked eye, be seen to consist of fine round balls which give the powder product a certain characteristicdifierence in appearance and handling qualities from the usual powders. Of course, if the particle size is excessively small, as for instance, where a substantial part of the product is asfine as 100 mesh size, the product becomes floury and dust-like in character even though the globular particle structure is present.

The individual component rounded particles of the present product are ordinarily hollow unitarybodies. Each particle is a detached unit consisting of a shell or wall of the dry soap material solidified into the characteristic rounded particle shape and enclosing within it a single void or hollow space. The unitary hollow particle structure is shown in Figure 4. This is in contrast to a spongy material consisting of granules or particles of sponge-like or honeycomb structure. In such products the component particles are usually of irregular fragmentary character and the interior of the particle is a mass of interlacing walls and pores rather than a single void. The thickness of the walls of the particles is controlled by the conditions of the process and may be varied depending upon the characteristic desired in the finished product such as particle size, bulking weight, speed of solubility. etc. The practical limiting minimum thinness of the particle walls is determined by the wall strength which is required to prevent the particles from crushing or breaking under the conditions normally encountered in bulking of the product in bins, handling it through conveyors and filling machines, and shipping it for use. The particles of the present product are made sufliciently stable so that they will withstand such normal handling and shipping conditions without breaking down. This hollow unitary particle structure is important 'inmaking the product quickly and completely soluble and at the same time providing a product of sub stantial particle size which is free from dust,

stable, and freeflowing.

Soap products made by spraying molten soap as heretofore proposed are normally of shredded and fragmentary particle form. The novel structure properties of the present product just described are the result of cercontains an appropriate amount of alkaline matter and which contains about 40% of water. This soap, taken from the kettles at temperatures of say to F., which temperatures are ordinarily attained in the manufacture of soap, does not give a satisfactory particle structure. A product produced from molten soap at this temperature is definitely characterized by excessive stringing 'and objectionable stretching out and elongation of the particles. Even with the other process variables at proper values this difiiculty in the product is still fairly evident with soap temperatures (the T, measurement described herein) of as high as say 200 F., although a product produced under this latter condition is much improved. The

evidence of shredding and stringing become less and the product improves with increase of temperature. With T values of say, 220 F., or more, practically all evidences of the objectionable shredding and stretching out of the particles disappears, and if the other process conditions are right the preferred characteristically rounded particle is obtained. The product of Figures 1 and 5 was produced with T,230 F.

Another factor which I have found to be of particular importance in obtaining from high solid content molten soap the characteristic rounded particle shape. free from shreds and the like, and the other distinctive properties above described, is the provision of an adequate amount of drying gas at a suitable initial temperature (T The condition appears to be essential. If it is not fulfilled the best particle structure cannot be obtained. At low initial air temperatures (T,) as, for instance, 200 F., the product consists of'chunks. shreds, and fragments which give it a matted fuzzy appearance which is in sharp contrast to the approportion of fairly regularly shaped rounded particles but also contains a fair proportion of irregular ragged fragments, distorted and extenuated particles, and at considerable quota of small dust-size fragments, which characteristics affect its appearance, handling properties, and the like. At initial temperatures of about 380 to 400 F. the

i misshaping and distortion of the particles characteristic in the products produced at low initial temperatures have begun definitely to disappear. The preferred product of the present invention is ordinarily made with initial temperatures in excess of 450 F., usually about 475 or 500 F. The product of Figures 1 and 5 was made at T 475 F. In carrying out the process an adequate amount of treating gas which has been suc-' cessfully used in the production of the preferred product at the rate of approximately a ton of substantially dry finished soap product per hour, produced from a corresponding amount of molten soap of about 40% water content sprayed through seven material.

(7) pressure spray nozzles is about 30,000 cubic feet of air per minute measured at 475 F. The diameter of the treating tower shown in the drawings is 20 ft. so that the cross sectional area of the stream of treating gas coming into contact with the sprayed soap is about 315 sq. ft., thus giving a mean air velocity of about 95 ft. per minute at the stated temperature. The soap spraying nozzles have discharge openings which are minute relative to the total cross sectional area of the tower as shown in the drawings, and

are about 1% millimeters in' diameter, thus affording a total cross sectional area of about 0.015 sq. in. for entrance of soap into the tower. As stated above, the temperatures just given are based ona soap product containing approximately 40% of water and an appropriate amount of an added alkaline These figures will depend somewhat on the particular composition and the water content of the product. For instance, I have been able to produce in a pure soap product having 30% of Water substantially as satisfactory a particle formation with an initial air temperature of 350 F. as can be obtained-in ordinary operation on the higher Water content product with a temperature 100 higher. The figures here given must, of course, be taken as illustrative of results which have been obtained under certain conditions with a particular soap product, and

they naturally are susceptible to a certain amount of variation 'depending'upon the kind of soap used, the particular design of apparatus employed, the kind of spray nozzles used, and the other process conditions. The conditions given and the product shown and described constitute a specific example of one embodiment of my invention, and this example together with the basic theory set forth in the specification furnish adequate, information for obtaining and controlling the same product properties with any particular kind of soap.

The necessity for having a proper soap temperature and a proper initial air temperature to obtain the best type of particle formation, particle structure, and the like, is probably due, at least in part, to the fact that-the soap leaving the spray nozzle is rendered non-stringing by a proper temperature and can thus break up into regular drops and that these drops emanating from the spray nozzles are quickly dried or solidified by the air at proper initial temperature and in adequate volume before they have opportunity to become distorted substantially from their rounded form. Where the drying gas coming into contact with the liquid spray is adequately hot and is supplied in adequate quantity it appears to exert a rapid drying action on the particles which quickly dries and solidifies the soap matter of each particle and holds it in a regular form. Where drying air of relatively low initial temperature is used the particles of the finished product show a greater distortion 'from smooth, regular rounded; form. With proper temperature conditions the generation of steam on the inside of the sprayed particles appears to exert an expansive effect which inflates the particles and promotes the regular generally globularshape. With a proper initial air temperature this inflation is effected to an appropriate degree and av quick solidification of the inflated particles in full rounded form occurs. The accuracy of this explanation is not insisted upon, but the fact is that for the best particle formation an adequately high initial temperature of the drying gas is important. For the best particle formation both an adequately high initial temperature of the drying gas and an adequately high' preheating temperature of the soap supplied to the spray nozzles are desired; The

practical upper limit for the initial temperature .of the drying gas is that temperature above which the particles of the prodnet are no longer properly formed and stable. If the initial temperature is too high, the particles become disrupted and have the appearance of broken shells. This condition probably results from an excessively rapid generation of steam in the particle due to the excessively high initial temperature, which steam exerts an explosive or disrupting action on the particle and in effect blows it apart or explodes it. The im portant and major portion of the evaporation and drying action occurs, however, by reason ofthe large volume of heated gas which is brought into contact with the sprayed material. This gas must be supplied in adequate quantity to quickly absorb and carry away the moisture removed from the soap stock and dust be supplied at an adequately high initial temperature as above described.

The process variables, particularly the temperature of the drying gas just discussed, are important in their effect on such physical properties of the product as the unitary hollow particle structure, the particle size, and correlated properties. The generation of steam within the sprayed particles of soap stock probably exerts an expansive or explosive action from within the particle which tends to inflate or puff up the particle. Now, if this particle is quickly dried a nicely shaped unitary particle of reasonably thin but stable wall structure containing a single hollow interior space is formed. Higher temperatures with correspondingly greater putting or explosive action produce larger more fully inflated particles. For instance, with a given soap and with all process conditions constant except the initial temperature of the drying gas, I have produced with an initial tern-'- perature of 350 F. particles having an average diameter of about 0.4 mm. with an initial temperature of 100 F. particles having an average diameter of between 0.5 and 0.6 mm., and with an initial temperature of 75" F. particles having an average diameter of 0.7 5 mm. The use of a high solid content molten soap is important in obtaining the characteristic large particles of independently visible size.

Ihe pressure on the soap as it is sprayed from the nozzle is another factor that is importantin its efi'ect on the physical proper-' ties of the product and in its relation to the preheating temperature of the soap and the initial temperature of the drying gas. EX- cessively low pressures, fora given nozzle, appear to promote irregularity of particle shape and to produce particles which are block shaped and chunky rather than smoothly rounded. In general the size of the particle decreases with increase in pressure. Variation-in pressure may conveniently be used to correct certain defects in the product. For instance, if with a given preheating temperature of the soap and a given temperature of'the drying gas, a high prortion of disrupted and exploded particles is obtained, this defect can be corrected within reasonable limits by an increase in the pressure which will produce smaller particles at the spray containing a lesser amount of water to be generated into steam, with the result that a less violent expansion or pufiing of the particles will result. These three principal variables of soap temperature, initial temperature of drying gas, and pressure on the soap as sprayed are essentially interrelated and are susceptible of variation within limits described herein. The actual pressure which. must be employed at the spray nozzles depends not only upon the particular physical'pro erties desired in the ultimate product but a so depends upon the particular kind and size of nozzle which is employed. The lower limit for the pressure is that at which a satisfactory spray without streaks or streams of liquid not broken up into drops is formed. Above this value the pressure should be regulated to control the particle size, shape and presence of exploded or disrupted particles along the lines out lined above. The best particle formation and control of conditions has been obtained with pressure type nozzles although reasonably good results under certain conditions have been obtained with atomizing nozzles. l/Vith pressure nozzles of conventional design pressures in excess of 100 lbs. per square inch and less than 350 lbs. per square inch have ordinarily been employed, a pressure of approximately 250 to 275 lbs. per square inch being satisfactory for the production of the preferred type of product above described and shown in Figures 1 and 5.

The structural; properties of the product which are obtained by the particular process of the invention, as above described, give to the present product qualities evident in the use of the product which have not been .obtamed-heretofore in soap products. A property of this nature, which is of paramount importance to its unability, is its quick and easy solubility.- The present product is quickly soluble even in water which is quite cool. When the present product is dropped on water and stirred an immediate diffusion of the soap particles takes place and a practically instantaneous formation of suds followed by a rapid disappearance of the soap particles occurs. The rapid solubility. of the present product is due, in considerable measure, to the large area accessible to the water which is presented by a given weight of the product. The particle walls are very thin. These walls can be made much thinner than soap flakes without rendering the particles too frail to be stable. The generally globular form of the hollow particles gives them a greater strength than could be obtained in other particle shapes. The particles do not break up under normal handling and shipping conditions. lVhen the product is poured lightly into a carton of dimensions 2%" x 6" x 8 'Cit can be shaken down in the carton a distance of about with a relatively small amount of shaking as, for instance, the amount of shaking a package normally receives in handling through the filling machine. This is a settling of approximately invention.

'minutes for complete solution.

9% calculated on the original volume of the product before settling. No further substantial settling in the carton occurs during extended handling and shaking of the carton as in shipment, and the like. The average thickness of particle wall in the preferred product described above and illustrated in Figures 1 and 2, as taken from measurements of a large ,number of typical particles, is about 0.047 mm. In the preferred product having the average wall thickness of 0.04.7 mm., the minimum wall thickness appears to be about 0.037 mm., while the maximum thickness appears to be about 0.074. mm. Thus all of the walls are very thin and the variation in Wall thickness in different particles is small. In the finest, most quickly soluble soap flakes at present commercially available, the average flake thickness appears to be about 0.172 mm., which is in excess of'four times the average wall thickness of the particles of the preferred product of this In such products the flakes are somewhat unstable and break downto a certain extent during handling so that a considerable amount of dust is present in the product. In some widely used flakes and chips the average flake thickness is greater than 0.3 mm.

In distilled water and tap Water of the average sort at 110 F., (luke Warm-slig'htly above body temperature) the present product, when stirred gently, is completely soluble in about 10 to 15 seconds. The average soap in powder form requires from 60 to 80 seconds. A few very fine dusty powders, some spongy granular or shredded soaps, and some of the finer soap flakes dissolve practically completely in from 30 to 60 seconds. But with such products, although the bulk of the product dissolves in say from 30 to 60 seconds, there are usually present in the product larger chunks and lumps which require much longer to dissolve completely. For instance, I have examined several products where the bulk of the product goes into solution in from 30 to 45 seconds but which have an appreciable amount of larger particles requiring from 1% to 4 These figures on speed of solubility were determined by placing grm. of soap product in A) liter of water at 110 F. and stirring the product with a tablespoon at the rate of 25 double strokes per quarter minute. The container holding the soap and water was provided with an internal removable screen which was lifted out of the water at desired intervals, say 10 to 15 seconds, and if any soap remained undissolved it could be seen on the screen. i

' The regular commercialrun of the present product exhibits a notable uniformity of .particle size. To the eye the product appears to be made up entirely of rounded-particles or balls of the same general order of magnitude in size, freefrom conspicuously large particles and substantially free from fine material ordust. When the product is viewed against and through a transparent surface, as, for'instance when it is placed in a glass container, the individuality and size uniformity of the particles are particularly evident as the particles lie in closely packed arrangement against the surface of the glass. Definite spaces or interstices be tween the particles are clearly evident, and these spaces appear clean and free from any dust or fine powder. These properties are illustrated in Figure 5. The product illustrated in Figures 2 and 3 is, as stated above, of an average particle size of about 0.7 5 mm. In this product substantially none of the particles are as large as 2 mm. in diameter; 100% of the product passes through a mesh sieve in which the openings are 2 mm. square. Of this same product 85% to 90% passes a 20 mesh sieve (sieve openings 1 mm. square) while only to of the product passes a mesh sieve (sieve openings 0.5 mm. square). Only about 5% to 8% of the product passes a mesh sieve (sieve openings 0.3 mm. square), and only about 1 to 3% of the product passes a 100 mesh sieve (sieve openings 0.15 mm. square).

The fact that no substantial part of the product is of sufficiently small particle size to pass a mesh sieve shows that the product is practically entirely free of objectionable fine material or dust. From the above figures it is seen that there is a variation of but 0.5 mm. in size between the maximum and minimum size particle in practically three-fourths of the total bulk of the prod uct, and this size variation occurs in particles ranging in size from 0.5 mm. to 1.0 mm. and averaging in size approximately 0.75 mm. Thus the variation in size between the maximum and minimum size particles in approximately three fourths of the total weight of the product is only about 67% of the size of the average size particle. This uniformity in particle, size is unusual for an average commercial run of a product of this class which has not been subjected to any screening operation. The present product consisting of the independent individually visible characteristic rounded particle's substantially free from 7 surface or break where the shifting action has exposed material which was previously below the surface. The exposed new surface is fiat and regular, free from the troughs or rifts which arecharacteristic in the handling of the average powder product. This property is illustrated in Figure 5. When the product is placed in a converging receptacle having an outlet at the bottom as, for instance, a funnel, the cone bottom of a collector or bin, etc., it flows out freely by gravity Without tendency to arch or bridge over above the outlet and thus stop the flow. This property is of specialvalue in'collecting, storing and packaging the product by means of automatic machinery, in dispensing the product by means of gravity flow dispensing machines; etc. the use of the product for the reason that the most convenient way for the user to get the product out of the package is to shake orpour it out, and the present product flows out freely and evenly through a small hole so that exactl the proper amount maybe used.

The pro uct composed of these hollow unitary rounded fairly large size particles is light bulking. This is due both to the fact that a substantial proportion of the space occupied by the particle is represented by the hollow space on the inside of the particle and the fact that the re ularly shaped relatively large particles 0 the product bulk with substantial voids between particles. I have produced soap products having the characteristic roperties referred to herein and having a ulking weight, expressed in terms of the weight of a corresponding volume of water, of 0.07. The relative bulking Weight of the soap stock from which this light product was produced is about 0.95; the relative bulking weight 'of a chilled solidified cake of soap made from this li uid stock is about 1.02; and the relative bul ing weight of such soap in dry pulverized form is about 0.55. The bulking weight of the product may be varied, within reasonable limits, by varyin the conditions of the process. The particifiar form of product shown in Figures 2 and 3 and described above, has a relative bulking weight of about 0.11. The relative bulking weight can be increased well above this value without difiiculty. I have produced soap products having a reasonable moisture content and having a reasonabl good particle shape, size and structure whic showed bulking weights of from 0.20 to 0.25. When dropped upon a quiet water surface the soap globules flow out evenl upon the water surface and all of them oat, Each )article is independent and no clinging or alling occurs.

The present invention, therefore, provides a new type of soap product in reasonably finely divided condition. This soap product differs from products of this general class It is also of importance in heretofore produced principally in its characteristic novel physical properties, substantially as described. These novel physical properties are obtained by a particular process of preparation and treatment.

the said component particles are used in mass rather than as separate entities and are characteristically of a generally rounded globular shape, so that the product is free from substantial amounts of fine dust-like matter and presents to the eye the characteristic and distinguishing appearance of a. large number of independently visible individually distinct little balls of soap as distinguished particularly from a powder subetantially as illustrated and described, and in which product the said component particlcs are capable of ready independent relative movement without clinging together which promotes ready separation of the said particles upon introduction of the product into water, are capable of maintaining their independent identity during dissolving without tending to form into a lump, and are all substantially immediately accessible to the solvent action of the water, whereby notably rapid and complete solubility is assured and a positive resistance to lumping and balling of the product not heretofore attained in soap products'is effected.

2. A spray processed soap product in which the component particles of the regular commercial run of the product are averagely hollow bodies of rounded generally ball-like shape sufliciently large to readily appear to the eye as independent individually distinct particles of reasonably uniform size and sufficiently small to constitute necessarily a. bulk soap product of such character that the said component particles are used in mass rather than as separate entities, and consist of a shell of dry soap material solidified into the said characteristic rounded shape embodying substantially a single principal void, all substantially as illustrated and described, and in which product the average typical in dividual hollow component articles compriseappreciable amounts 0 soap so that the respective particles are individually distinct bodies capable of ready independent relative movement and ready separation upon introduction into water, are capable of attaining practically immediate contact with water upon being dropped upon the surface thereof and of maintaining their independent identity without sticking together to form masses of undissolved soap, and are large considering the amount of soap contained therein to thereby present an available surface area which is large relative to the amount of soap in the particle, whereby the said soap product is-free from any substantial characterizing amount of powder or dust-like matter, is soluble with particular readiness, speed and completeness, and is characterized by a total absence of any tendency to form lumps, balls or spots of undissolved soap in washing.

3. A spray processed bulk soap product of such character that the individual particles of the product are used in mass rather than as separate entities which, in its regular commercial run, is composed of particles that are of characteristically rounded hollovv. generally globular form, substantially as illustrated and described, and are of an average size of not less than 0.3 millimeter, as evidenced by the fact that a preponderating proportion of the product is retained on a 60 mesh sieve, substantially as described, which product possesses a speed of solubility at'least comparable with finely comminuted or flaked soap and is further characterized by freedom from any substantial amount of powder or dust-like material and particularly by freedom from any tendency to lump or mass in water.

4. A spray processed soap product composed principally of independently constituted individually distinct hollow particles of gener ally rounded conformation substantially as illustrated and described, having an average size sufliciently large so that no considerable proportion of the product passes a 60 mesh sieve; substantially as described, and suiliciently small so that the product is necessarily a bulk product of such character that the individualparticles of the soap are uesd in massrather than as separate entities and which, when placedin distilled water at 110 F. in the proportion of gram of the soap product to liter of water and stirred with a tablespoon at the rate of 25 double strokes per 4 minute, substantially as described, dissolves substantially completely,-as evidenced by the absence of any substantial proportion of undissolved particles when the soap containing water passes through a 60 mesh sieve, in a period of time not substantially exceeding 15 seconds.

5. A spray processed bulk soap product of such character that the individual particles of the soap are used in mass rather than as separate entities wherein the component particles of the regular commercial run are individually distinct hollow unitary bodies of rounded generally ball-like shape, substantially as illustrated and described, exceeding 0.3 millimeter in average minimum dimension as determined by the major portion of the product being retained-on a 60 mesh sieve;--substantially as described and individually constituted as independent particles consisting of a shell of dry-soap materialrof thickness averagely not exceeding 0.1 millimeter solidified into the said characteristically rounded shape embodying substantially a single principal voil, the relatively large hollow form and the individually distinct character of said particles giving to the product the property of definitely resisting formation of masses of undissolved soap in water and the thinness of the soap matter of the respective particles affording a particularly rapid speed of solubility, the product being further characterized by the fact that it does not break down into small particles or dust to any substantial extent and does not shake down in the cartons to any substantial extent during packaging and shipment. v

6. A spray processed substantially dry soap product free from substantial amounts of fine powder-like material composed of independent hollow rounded generally globular particles, substantially as illustrated and described, of average minimum dimension not less than 0.3 millimeter, as determined by the major portion of the product being retained on a 60 mesh sieve, nor more than 2 millimeters, as determined by the major portion of the product passing a 10 mesh sieve,

and of bulking weight not greater than.0.2

that of water nor lessthan 0.07 that of Water, whereby the said soap product dissolves completely in a articularly short time, offers a positive resistance to forming masses of undissol'ved soap in water, an floats on water in its substantial entirety in non-massing condition until completely diszsolved.

he process of producing a soap prodnot in characteristically rounded hollow generally globular particle form; substantially as illustrated and vdescribed, which comprises preparing, a molten soap, maintaining the temperature of said molten soa sufficiently high so that it is reasonably flui and can be reduced b spraying to reasonably finely divided con ition without stretching and stringing of the soap material,v

spraying the said soap to thus reduce it to said reasonably finely divided condition, and converting the sprayed molten soap into particles having said rounded generally globular sha e with V0ldS Wl th1Il said respective particles and solidifying said particles into the said hollow rounded generally globular shape by bringing into contact with said sprayed molten soap a current of treating gas heated to a sufficiently high temperature and supplied in large quantity sufficient relative to the amount of soap being sprayed that the said conversion of the sprayed soa particles takes place without reduction 0 the temperature of the "as below the effective treating temperature before the particles assume a permanent form-retaining condition, whereby formation of said rounded generally globular hollow particles accompanied and followed by removal and absorption of moisture from the said sprayed soap particles and consequent solidification of the particles into said rounded generally globular hollow shape is effected.

8. The process of producing a reasonably finely divided soap in characteristically rounded hollow generally globular particle form; substantially as illustrated and described, which comprises preparing a molten soap containing the usual relatively high percentage of solids ordinarily attained in such molten soap as commonly manufactured, spraying said soap in finely divided condition and effecting formation of the said characteristically rounded hollow generally globular particles of soap and solidification thereof into permanent form-retaining condition by preheating the said soap so that at the time the said soap is sprayed it is at a temperature in excess of 200 F., and by bringing into contact with said sprayed molten soap a current of treating gas heated to a temperature of at least 300 F. when it first contacts with the sprayed particles of soap and supplied in large quantity sufiicient relative to the amount of soap being sprayed that the said formation of the soap particles takes place without reduction of the temperature of the gas below its effec tive treating temperature before the said particles assume a permanent form-retainmg condition, whereby formation of said rounded hollow generally globular soap particles and solidification thereof is effected. 9. The process of producing a reasonably finely divided soap in characteristically rounded hollow generally ball-like particle form, which comprises preparing a molten soap containing the usual relatively high percentage of solids ordinaril attained in such soap as commonly manu actured, spraying said soap in reasonably finely divided condition, reheating the said soap so that atthe time o spraying the temperature thereof is sufficiently high to insure formation of a good spray free from stretching and stringing of the soap material, converting the sprayed molten soap into particles having said rounded generally ball-like shape with voids within said respective particles and solidifying said particles into the said hollow rounded generally ball-like shape by bringing into contact with said sprayed molten soap a current of treating gas heated to a temperature of at least 300 F. and supplied in large quantity sufiicient relative to the amount of soap being sprayed that the said conversion of the sprayed soa particles takes place without reduction 0' the temperature of the gas below the effective treating temperature before the particles assume a permanent form-retaining condition, whereby formation of said rounded hollow generally ball-like particle; accompanied and followed by removal and absorption of moisture from said sprayed soap particles and consequent solidification of the articles into said rounded hollow generally all-like shape is effected.

10. The process of producing a reasonably finely divided soap in characteristically rounded hollow generally ball-like particle form, which comprises preparing a molten soap consisting of substantially pure soap and having a water content of the general order of 30%, spraying said molten soap into a current of treating gas, preheating the said soap so that at the time of spraying it is at a temperature of the general order of 220 F. to thereby favor the formation of a good spray without stretching and stringing of the soap material, and effecting formation of the said characteristically rounded hollow generally ball-like soap particles and solidification thereof into permanent formretaining condition by bringing into contact with said sprayed molten soap a current of treating gas heated to a temperature of approximately 350 F. as it first contacts with the sprayed molten soap and supplied in large quantity sufiicient relative to the amount of soap being sprayed that the said formation of the soap particles takes place without reduction of the temperature of the gas below its effective treating temperature before the said particles assume a ermanent formretaining condition, where formation of said rounded hollow generall y ball-like soap particles and solidification thereof is effected.

11. The process of producing a reasonably finely divided soap product in characteristically rounded hollow globular ball-like form, which comprises preparing a molten soap consisting of substantially pure soap and an appropriate added alkaline material in the proportion of not more than a 1:2 ratio of alkaline material to soap solids and having a water content of the general order of 40%, spraying said soap into a current of treating gas, preheating the said soap so that at the time of spraying the temperature thereof is of the general order of 220 F. to thereby favor the formation of a good spray without stretching and stringing of the soap material, and effecting formation of the said characteristically rounded hollow generally ball-like soap particles and solidification thereof into permanent form-retaining con llO dition by bringing into contact with said sprayed molten soap a current of treating gas heated to a temperature of approximately 450 F. as it first contacts with the sprayed molten soap and supplied in large quantity suificient relative to the amount of soap being sprayed that the said formation of the soap particles takes place Without reduction Certificate of Correction.

Patent No. 1,652,900.

Granted December 13, 1927, to

DALLAS R. LAMONT.

It is hereby certified that error appears in the printed specification of the above numbered patent requiring correction as follows: Page 3, line 79, for the word larger read large; page 4, line 123, for the word The read Thee,- page 6, line 11, for the word dust read must; and line 107, for unabll ty read ueabilih page 9, line 78, claim 5, for voil read @0605; and that the said Letters Patent should be read With these corrections therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 10th day of January, A. D. 1928.

M. J. MOORE, Acting Uommz'eaioner of Patents. 

